Deformation and Damage Analysis of a Hybrid‐Forming Tool under Thermal Shock Conditions

Abstract

AbstractIn the hybrid–forming process for gradient structures [1] inhomogeneous cyclic thermo–mechanical stresses and strains lead to higher risks of failure of the forming tool. The main topic of this paper is the validation of finite element calculations for a tool–like specimen under complex thermo–mechanical loadings in order to predict the material behaviour [3]. To this end thermal shock experiments of tool–like specimens are performed. Optical measuring systems are used for three–dimensional digitalisation of the specimens to get a sufficient amount of data. Results of experimental optical measurings and results of finite element calculations are compared. Additionally, damage analysis using the eddy current method is performed to characterize the surface state of the cyclically thermal shocked specimens. This damage analysis provides data for lifetime prediction models under thermal shock conditions. (© 2008 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)